EP2097479A1 - Organic powder filler useful as the replacement of mineral filler in composites - Google Patents
Organic powder filler useful as the replacement of mineral filler in compositesInfo
- Publication number
- EP2097479A1 EP2097479A1 EP07856792A EP07856792A EP2097479A1 EP 2097479 A1 EP2097479 A1 EP 2097479A1 EP 07856792 A EP07856792 A EP 07856792A EP 07856792 A EP07856792 A EP 07856792A EP 2097479 A1 EP2097479 A1 EP 2097479A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- organic filler
- gel coat
- filler
- organic
- coat composition
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000000843 powder Substances 0.000 title claims abstract description 19
- 239000002131 composite material Substances 0.000 title claims abstract description 16
- 239000012764 mineral filler Substances 0.000 title claims abstract description 7
- 239000000945 filler Substances 0.000 title claims description 14
- 239000000463 material Substances 0.000 claims abstract description 23
- 239000002245 particle Substances 0.000 claims abstract description 16
- 239000000203 mixture Substances 0.000 claims description 37
- 239000012766 organic filler Substances 0.000 claims description 36
- 229920005989 resin Polymers 0.000 claims description 32
- 239000011347 resin Substances 0.000 claims description 32
- 229920006337 unsaturated polyester resin Polymers 0.000 claims description 14
- 239000007795 chemical reaction product Substances 0.000 claims description 13
- 239000000178 monomer Substances 0.000 claims description 13
- 238000000034 method Methods 0.000 claims description 9
- 229920001169 thermoplastic Polymers 0.000 claims description 9
- 239000011368 organic material Substances 0.000 claims description 8
- 230000008569 process Effects 0.000 claims description 6
- 229920000877 Melamine resin Polymers 0.000 claims description 5
- 229920006397 acrylic thermoplastic Polymers 0.000 claims description 5
- 239000003999 initiator Substances 0.000 claims description 5
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 claims description 5
- 238000000465 moulding Methods 0.000 claims description 5
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 5
- 229920002635 polyurethane Polymers 0.000 claims description 5
- 239000004814 polyurethane Substances 0.000 claims description 5
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 claims description 5
- 229920006305 unsaturated polyester Polymers 0.000 claims description 5
- 150000001875 compounds Chemical class 0.000 claims description 4
- 239000011159 matrix material Substances 0.000 claims description 4
- 239000000047 product Substances 0.000 claims description 4
- 238000005549 size reduction Methods 0.000 claims description 4
- 230000009477 glass transition Effects 0.000 claims description 3
- 230000004888 barrier function Effects 0.000 claims description 2
- 238000010438 heat treatment Methods 0.000 claims description 2
- 241000237519 Bivalvia Species 0.000 claims 1
- 235000020639 clam Nutrition 0.000 claims 1
- 239000003039 volatile agent Substances 0.000 claims 1
- 239000011256 inorganic filler Substances 0.000 abstract description 4
- 229910003475 inorganic filler Inorganic materials 0.000 abstract description 4
- 229910052500 inorganic mineral Inorganic materials 0.000 abstract description 3
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 7
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 7
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 6
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 5
- 239000002253 acid Substances 0.000 description 5
- 150000008064 anhydrides Chemical class 0.000 description 5
- 229920003023 plastic Polymers 0.000 description 5
- 239000004033 plastic Substances 0.000 description 5
- 229920001187 thermosetting polymer Polymers 0.000 description 5
- 239000004416 thermosoftening plastic Substances 0.000 description 5
- OMPJBNCRMGITSC-UHFFFAOYSA-N Benzoylperoxide Chemical compound C=1C=CC=CC=1C(=O)OOC(=O)C1=CC=CC=C1 OMPJBNCRMGITSC-UHFFFAOYSA-N 0.000 description 4
- 235000019400 benzoyl peroxide Nutrition 0.000 description 4
- 239000003054 catalyst Substances 0.000 description 4
- 239000004615 ingredient Substances 0.000 description 4
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 description 4
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 4
- 229920002554 vinyl polymer Polymers 0.000 description 4
- 239000004342 Benzoyl peroxide Substances 0.000 description 3
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 3
- 239000010438 granite Substances 0.000 description 3
- 239000000049 pigment Substances 0.000 description 3
- 235000013772 propylene glycol Nutrition 0.000 description 3
- 150000005846 sugar alcohols Polymers 0.000 description 3
- PUPZLCDOIYMWBV-UHFFFAOYSA-N (+/-)-1,3-Butanediol Chemical compound CC(O)CCO PUPZLCDOIYMWBV-UHFFFAOYSA-N 0.000 description 2
- MYRTYDVEIRVNKP-UHFFFAOYSA-N 1,2-Divinylbenzene Chemical compound C=CC1=CC=CC=C1C=C MYRTYDVEIRVNKP-UHFFFAOYSA-N 0.000 description 2
- OZAIFHULBGXAKX-UHFFFAOYSA-N 2-(2-cyanopropan-2-yldiazenyl)-2-methylpropanenitrile Chemical compound N#CC(C)(C)N=NC(C)(C)C#N OZAIFHULBGXAKX-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000008199 coating composition Substances 0.000 description 2
- GGSUCNLOZRCGPQ-UHFFFAOYSA-N diethylaniline Chemical group CCN(CC)C1=CC=CC=C1 GGSUCNLOZRCGPQ-UHFFFAOYSA-N 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 150000002978 peroxides Chemical class 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000011342 resin composition Substances 0.000 description 2
- 229920006395 saturated elastomer Polymers 0.000 description 2
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical compound OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000004575 stone Substances 0.000 description 2
- 230000009974 thixotropic effect Effects 0.000 description 2
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 2
- -1 unsaturated dicarboxylic acid compound Chemical class 0.000 description 2
- FVQMJJQUGGVLEP-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy 2-ethylhexaneperoxoate Chemical compound CCCCC(CC)C(=O)OOOC(C)(C)C FVQMJJQUGGVLEP-UHFFFAOYSA-N 0.000 description 1
- DNIAPMSPPWPWGF-GSVOUGTGSA-N (R)-(-)-Propylene glycol Chemical compound C[C@@H](O)CO DNIAPMSPPWPWGF-GSVOUGTGSA-N 0.000 description 1
- ZQHJVIHCDHJVII-OWOJBTEDSA-N (e)-2-chlorobut-2-enedioic acid Chemical compound OC(=O)\C=C(\Cl)C(O)=O ZQHJVIHCDHJVII-OWOJBTEDSA-N 0.000 description 1
- 229940058015 1,3-butylene glycol Drugs 0.000 description 1
- LGJCFVYMIJLQJO-UHFFFAOYSA-N 1-dodecylperoxydodecane Chemical compound CCCCCCCCCCCCOOCCCCCCCCCCCC LGJCFVYMIJLQJO-UHFFFAOYSA-N 0.000 description 1
- BJELTSYBAHKXRW-UHFFFAOYSA-N 2,4,6-triallyloxy-1,3,5-triazine Chemical compound C=CCOC1=NC(OCC=C)=NC(OCC=C)=N1 BJELTSYBAHKXRW-UHFFFAOYSA-N 0.000 description 1
- JAHNSTQSQJOJLO-UHFFFAOYSA-N 2-(3-fluorophenyl)-1h-imidazole Chemical compound FC1=CC=CC(C=2NC=CN=2)=C1 JAHNSTQSQJOJLO-UHFFFAOYSA-N 0.000 description 1
- OCXPJMSKLNNYLE-UHFFFAOYSA-N 2-prop-2-enylbutanedioic acid Chemical compound OC(=O)CC(C(O)=O)CC=C OCXPJMSKLNNYLE-UHFFFAOYSA-N 0.000 description 1
- DXIJHCSGLOHNES-UHFFFAOYSA-N 3,3-dimethylbut-1-enylbenzene Chemical compound CC(C)(C)C=CC1=CC=CC=C1 DXIJHCSGLOHNES-UHFFFAOYSA-N 0.000 description 1
- JLBJTVDPSNHSKJ-UHFFFAOYSA-N 4-Methylstyrene Chemical compound CC1=CC=C(C=C)C=C1 JLBJTVDPSNHSKJ-UHFFFAOYSA-N 0.000 description 1
- FBPFZTCFMRRESA-KVTDHHQDSA-N D-Mannitol Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@H](O)CO FBPFZTCFMRRESA-KVTDHHQDSA-N 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- 239000004606 Fillers/Extenders Substances 0.000 description 1
- 229930195725 Mannitol Natural products 0.000 description 1
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- KDYFGRWQOYBRFD-UHFFFAOYSA-N Succinic acid Natural products OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 238000012644 addition polymerization Methods 0.000 description 1
- 150000001336 alkenes Chemical group 0.000 description 1
- RREGISFBPQOLTM-UHFFFAOYSA-N alumane;trihydrate Chemical compound O.O.O.[AlH3] RREGISFBPQOLTM-UHFFFAOYSA-N 0.000 description 1
- QUDWYFHPNIMBFC-UHFFFAOYSA-N bis(prop-2-enyl) benzene-1,2-dicarboxylate Chemical compound C=CCOC(=O)C1=CC=CC=C1C(=O)OCC=C QUDWYFHPNIMBFC-UHFFFAOYSA-N 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 235000019437 butane-1,3-diol Nutrition 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- KTVZZJJSXSGJSX-UHFFFAOYSA-N carbonic acid;2-propan-2-ylperoxypropane Chemical compound OC(O)=O.CC(C)OOC(C)C KTVZZJJSXSGJSX-UHFFFAOYSA-N 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- HNEGQIOMVPPMNR-IHWYPQMZSA-N citraconic acid Chemical compound OC(=O)C(/C)=C\C(O)=O HNEGQIOMVPPMNR-IHWYPQMZSA-N 0.000 description 1
- 229940018557 citraconic acid Drugs 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000006482 condensation reaction Methods 0.000 description 1
- 239000007822 coupling agent Substances 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- LSXWFXONGKSEMY-UHFFFAOYSA-N di-tert-butyl peroxide Chemical compound CC(C)(C)OOC(C)(C)C LSXWFXONGKSEMY-UHFFFAOYSA-N 0.000 description 1
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 1
- SZXQTJUDPRGNJN-UHFFFAOYSA-N dipropylene glycol Chemical compound OCCCOCCCO SZXQTJUDPRGNJN-UHFFFAOYSA-N 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 235000011187 glycerol Nutrition 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- XXMIOPMDWAUFGU-UHFFFAOYSA-N hexane-1,6-diol Chemical compound OCCCCCCO XXMIOPMDWAUFGU-UHFFFAOYSA-N 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- 239000000594 mannitol Substances 0.000 description 1
- 235000010355 mannitol Nutrition 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- HNEGQIOMVPPMNR-NSCUHMNNSA-N mesaconic acid Chemical compound OC(=O)C(/C)=C/C(O)=O HNEGQIOMVPPMNR-NSCUHMNNSA-N 0.000 description 1
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 description 1
- HNEGQIOMVPPMNR-UHFFFAOYSA-N methylfumaric acid Natural products OC(=O)C(C)=CC(O)=O HNEGQIOMVPPMNR-UHFFFAOYSA-N 0.000 description 1
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 description 1
- 229920005906 polyester polyol Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 239000004848 polyfunctional curative Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 150000003254 radicals Chemical class 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 125000003011 styrenyl group Chemical group [H]\C(*)=C(/[H])C1=C([H])C([H])=C([H])C([H])=C1[H] 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/65—Additives macromolecular
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K11/00—Use of ingredients of unknown constitution, e.g. undefined reaction products
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
- C08L67/06—Unsaturated polyesters
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L75/00—Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
- C08L75/04—Polyurethanes
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/66—Additives characterised by particle size
- C09D7/68—Particle size between 100-1000 nm
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/66—Additives characterised by particle size
- C09D7/69—Particle size larger than 1000 nm
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
- Y10T428/2991—Coated
Definitions
- the present invention is in the field of gel coats, more particularly, gel coat compositions with an organic powder filler material and articles coated with such gel coats.
- Gel coated composite articles are commonly used in a wide variety of applications.
- Gel coats provide improved weathering characteristics and surface appearance.
- the composite article preferably simulates the appearance of natural materials such as granite, marble or other stone.
- a number of methods are known to produce the simulated stone appearance.
- US patent 5,504,126 described a simulated mineral article comprises a discrete suspended plastic material and a continuous thermoplastic matrix. The plastic material and the thermoplastic matrix are visually distinguishable from each other and each contains a coupling agent.
- the patent also provides a method of preparing a simulated mineral article which entails preparing a liquid thermoplastic to serve as a matrix and then suspending a plastic material therein.
- the plastic material is composed of a thermoset plastic made from resin which comprises an acid component having thermoplastic characteristics.
- US patent 5,476,895 describes a sprayable coating composition that is useful for forming a simulated granite surface having high-impact strength, superior hardness and an aesthetically-pleasing look.
- the coating composition has a gel coat and granules which include thermoplastic and thermoset plastic components.
- the gel coat and granules are visually differentiable from each other, substantially immiscible and substantially isopycnic in density.
- the composition when combined with a hardener, may be sprayed into a mold and backed with fiber glass, plastic or other suitable resin to form a panel or similar structure, or may be directly applied to a surface to provide a simulated-granite appearance.
- JP 02-102156 described a hot press molding resin composition to improve transparency and gloss by hot-pressing a molding composition containing an unsaturated polyester resin, curing agent, cured product powder of an unsaturated polyester resin, specific inorganic filler and mold releasing agent.
- JP 06-25539 described colored resin particles for decorated moldings. The colored resin particles were obtained by dissolving the thermoplastic resin, in uncured thermosetting resin. Filler and pigment were then added into the resin solution and the resin solution was cured and crushed into small pieces.
- the invention is an organic filler useful as the replacement of mineral fillers in gel coats and other type of composites materials, the organic filler comprising from about 50 to 100 wt%, based on the total weight of the filler, of an organic material that comprises at least one of : (a) the reaction products of unsaturated polyester resins, unsaturated polyester/polyurethane hybrid resins, cross-linkable acrylics, melamine, or (b) thermoplastic polymers that are neither soluble in, nor swellable in ethylenically unsaturated monomers.
- the invention is a gel coat composition
- a gel coat composition comprising an organic filler, the organic filler comprising from about 50 to 100 wt%, based on the total weight of the filler, of an organic material that comprises at least one of : (a) the reaction products of unsaturated polyester resins, unsaturated polyester/polyurethane hybrid resins, cross-linkable acrylics, melamine, or (b) thermoplastic polymers that are neither soluble in, nor swellable in ethylenically unsaturated monomers.
- the said total filler weight should preferably not exceed 50 weight % of the total gel coat composition.
- the invention does also relate to the resulting gel coat and the article comprising such a gel coat. Other uses are also part of the invention, in coatings such as barrier or skin coats or in composites molding compositions (BMC/SMC composites) and resulting articles.
- the invention firstly relates to powder organic filler materials (organic filler) useful as the replacement of mineral fillers, such as aluminum trihydrate, barium sulfate, calcium carbonate, talc, clay, etc., in gel coats, and other type of composite materials.
- the mineral filler can be entirely or partially replaced by the powder material in the application.
- the powder materials are made from organic materials.
- the amount of organic filler material to inorganic filler material in the gel coat composition is from 50/50 to 100/0 by weight, the total of the filler (organic filler + inorganic filler) not exceeding 50% of the total gel coat composition.
- the maximum particle size of the powder organic filler materials is less than 60 ⁇ m. More preferably, the particle size of the organic filler has a typical range of 0.1 to 45 ⁇ m, and is visually non-differentiable when incorporated into the gel coats or composites.
- the organic materials used to make the organic filler powders are a) the reaction products of unsaturated polyester resins, unsaturated polyester/polyurethane hybrid resins, cross-linkable acrylics, and melamine, or b) thermoplastic polymers that do neither dissolve in (not soluble in) nor swell in (not swellable in) ethylenically unsaturated monomers.
- the organic filler materials have glass transition temperature above 50°C, preferably above 60°C.
- the reaction products have a degree of cure (conversion) above 70%, preferably above 80%.
- the reaction products have less than 10 wt% volatile content, preferably less than 5% volatile content.
- the unsaturated polyester resin has at least one dicarboxylic alkene moiety and is preferably an oligomer of an ⁇ , ⁇ -ethylenically unsaturated dicarboxylic acid compound obtained by the condensation reaction of one or more of a saturated di- or polycarboxylic acid or anhydride and an unsaturated di- or polycarboxylic acid or anhydride with a glycol or a polyhydric alcohol.
- the unsaturated polyester resin can also be prepared from unsaturated di- or polycarboxylic acid(s) or anhydride(s) with glycols and/or polyhydric alcohol(s).
- saturated di- or polycarboxylic acids examples include isophthalic, orthophthalic, terephthalic, adipic, succinic, sebacic acid and mixtures of two or more of these compounds with isophthalic acid being preferred.
- Typical unsaturated carboxylic acids or anhydrides include maleic acid, fumaric acid, citraconic acid, chloromaleic acid, allyl succinic acid, itaconic acid, mesaconic acid, their anhydrides and mixtures of two or more such compounds, with maleic anhydride being the preferred choice.
- polyhydric alcohols which are useful in the invention include neopentyl glycol, ethylene glycol, di ethylene glycol, tri ethylene glycol, propylene glycol, dipropylene glycol, 1,4- butanediol, polyethylene glycols, glycerol, mannitol, 1,2-propanediol, pentaerythritol, 1,6- hexanediol, 1,3-butylene glycol and mixtures of two or more of such compounds.
- the production of such resins is well-known to those skilled in the art and, additionally, many suitable resins are commercially available from resin manufacturers, such as Cook Composites & Polymers Company.
- the unsaturated polyester resin solution also contains ethylenically unsaturated monomer.
- the ethylenically unsaturated monomer can be any ethylenically unsaturated monomer capable of crosslinking the unsaturated polyester resin via vinyl addition polymerization.
- Examples of useful ethylenically unsaturated monomers are styrene, o-, m-, p- methyl styrene, methyl acrylate, methyl methacrylate, t-butylstyrene, divinyl benzene, diallyl phthalate, triallyl cyanurate and mixtures of two or more unsaturated monomers.
- the preferred monomer is styrene because it provides an economical monomer solution.
- thermosetting resins The reaction products are made through the typical curing processes of thermosetting resins.
- the typical curing process of thermosetting resin comprises adding initiators and promoters to a resin or resin solution and by (i) curing at ambient - A -
- the cured materials can be post-cured at elevated temperature to further increase the degree of cure and removal of the volatile materials.
- the cured organic materials then went through a size reduction process to obtain the final powder product with proper size range.
- the traditional size reduction process includes ball mill, cryogenic grinding, hammer mill, jet mill, roller mill, etc.
- the initiators useful in producing the cured resin compositions of this invention are vinyl polymerization catalysts such as peroxides, persulfides, perborates, percarbonates, and azo compounds or any other suitable catalyst capable of catalyzing the vinyl polymerization of the polyester polyol and/or the ethylenically unsaturated monomer.
- vinyl polymerization catalysts such as peroxides, persulfides, perborates, percarbonates, and azo compounds or any other suitable catalyst capable of catalyzing the vinyl polymerization of the polyester polyol and/or the ethylenically unsaturated monomer.
- BPO benzoyl peroxide
- TBPB tertiarybutyl peroxybenzoate
- 2,2'-azo-bis-isobutyronitrile dibenzoyl peroxide
- lauryl peroxide di-t-butyl peroxide
- diisopropyl peroxide carbonate and t-butyl peroxy-2-ethylhexanoate.
- Promoters can also be used in combination with vinyl polymerization peroxide catalysts to control the rate of free radical initiation.
- a common benzoyl peroxide promoter is N,N- diethylaniline.
- Gel coat compositions can be formulated with the organic filler powder of this invention in the usual method.
- Gel coat compositions include pigment, promoters, catalysts, stabilizers, extenders, and the like as practiced in the art.
- the amount of organic filler powder material in gel coat composition is of at least about 2 wt%, preferably from about 2 wt% to about 50 wt%, more preferably from about 10 wt% to about 50 wt% of total gel coat formula, with HAP value of less than about 37%.
- the total filler weight does not exceed 50% of the total weight of the gel coat composition.
- the gel coat materials with the organic powder have uniform color appearance and have improved color stability when exposed to moisture.
- TBPB 1.5 wt% initiators
- PG/NPG/IPA/MA propylene glycol/neopentyl glycol/isophthalic acid/maleic anhydride
- the resin used was a base resin in CCP STYPOL brand gel coats.
- the resin solution was poured into metal mold at 150°C and cured for 3 minutes. The cured resin was then broken into small pieces about 1 square inches. The pieces were then grinded to powder with the maximum particle size of 45 ⁇ m with a hammer mill.
- 0.15% of 6% cobalt and 1.5 wt% initiators methyl ethyl Ketone peroxide (MEKP) was added into an unsaturated polyester resin containing 60 wt% PG/NPG/IPA/MA type resin solid and 40 wt% styrene monomer (the same resin as used in Example 1).
- the resin solution was poured into a metal mold at ambient temperature and cured for 12 hours.
- the cured resin was then post-cured at 65 °C for 24 hours and broken into small pieces about 1 square inches. The pieces were then grinded to powder with the maximum particle size of 45 ⁇ m with a hammer mill.
- a gel coat composition is then prepared by blending the following ingredients :
- a gel coat composition is then prepared by blending the following ingredients Table 2
- a low VOC gel coat composition is then prepared by blending the following ingredients :
- the gel coat from Example 3 was very stable in that it did not gel after three months storage.
- the gel coat of Example 4 was not stable in that it gelled within one week.
- Pigmented gel coat compositions were prepared by adding 7.5 wt% black pigment paste into the gel coat composition shown in Examples 3 and 5 : Table 4
- the resulting gel coats had a Brookfield viscosity of 18000 - 20000 cps at 4 rpm at 77°C and a thixotropic index of 5.0-7.0. 1.8% methyl ethyl ketone peroxide (MEKP) is used to cure the gel coat. The gel time is around 15 minutes and cure time is around 60 minutes.
- Two gel coated laminates were prepared by spraying the catalyzed gel coat onto a mold and letting the gel coat cure at the ambient temperature for about one hour. The laminate was then put on the gel coat to about 3.5 mm in thickness. The color of cured gel coat was measured by a spectrophotometer.
- the gel-coated laminates were prepared with the gel coat samples from Examples 6 and 7.
- the laminates had the cured gel coat thickness around 15 mils.
- the panels were immersed in boiling de-ionized water for 100 hours, and the color difference before and after boil test was measured by a spectrophotometer. The results indicated the gel coat sample from Example 6 has much less color change compared to the gel coat sample from Example 7. Table 6
- the resulting gel coat samples had a Brookfield viscosity of 8000 - 14000 cP (mPa.s) at 4 rpm at 77 0 C and a thixotropic index of 4.0-6.5.
- the gel coats were then initiated with 1.8% methyl ethyl ketone peroxide (MEKP) and sprayed onto glass mold with various thicknesses.
- MEKP methyl ethyl ketone peroxide
- the gel coats had gel time around 15 minutes and cure time around 60 minutes.
- the cured gel coat films were then checked for the porosity.
- Cured gel coat films of Examples 9 to 11 showed porosity at the gel coat thickness around 15, 27, and 40 mils (0.38, 0.69 and 1.02 mm).
Abstract
Description
Claims
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PL07856792T PL2097479T3 (en) | 2006-12-29 | 2007-12-17 | Organic powder filler useful as the replacement of mineral filler in composites |
EP07856792A EP2097479B1 (en) | 2006-12-29 | 2007-12-17 | Organic powder filler useful as the replacement of mineral filler in composites |
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US88264906P | 2006-12-29 | 2006-12-29 | |
PCT/EP2007/001695 WO2008080440A1 (en) | 2006-12-29 | 2007-02-28 | Organic powder useful as the replacement of mineral filler in composites |
US97959007P | 2007-10-12 | 2007-10-12 | |
US11/876,046 US8906502B2 (en) | 2006-12-29 | 2007-10-22 | Organic powder useful as the replacement of mineral filler in composites |
PCT/EP2007/011055 WO2008080550A1 (en) | 2006-12-29 | 2007-12-17 | Organic powder filler useful as the replacement of mineral filler in composites |
EP07856792A EP2097479B1 (en) | 2006-12-29 | 2007-12-17 | Organic powder filler useful as the replacement of mineral filler in composites |
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EP2097479A1 true EP2097479A1 (en) | 2009-09-09 |
EP2097479B1 EP2097479B1 (en) | 2010-06-30 |
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EP07856792A Active EP2097479B1 (en) | 2006-12-29 | 2007-12-17 | Organic powder filler useful as the replacement of mineral filler in composites |
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US (1) | US8906502B2 (en) |
EP (1) | EP2097479B1 (en) |
KR (1) | KR101468240B1 (en) |
AT (1) | ATE472575T1 (en) |
AU (1) | AU2007341656B2 (en) |
BR (1) | BRPI0722052B1 (en) |
CA (1) | CA2671089C (en) |
DE (1) | DE602007007516D1 (en) |
EA (1) | EA019218B1 (en) |
ES (1) | ES2347922T3 (en) |
MX (1) | MX2009006426A (en) |
MY (1) | MY152134A (en) |
PL (1) | PL2097479T3 (en) |
WO (1) | WO2008080550A1 (en) |
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WO2006036969A2 (en) | 2004-09-28 | 2006-04-06 | Atrium Medical Corporation | Formation of barrier layer |
WO2006036982A2 (en) | 2004-09-28 | 2006-04-06 | Atrium Medical Corporation | Drug delivery coating for use with a stent |
US9012506B2 (en) | 2004-09-28 | 2015-04-21 | Atrium Medical Corporation | Cross-linked fatty acid-based biomaterials |
US9000040B2 (en) | 2004-09-28 | 2015-04-07 | Atrium Medical Corporation | Cross-linked fatty acid-based biomaterials |
US9801982B2 (en) | 2004-09-28 | 2017-10-31 | Atrium Medical Corporation | Implantable barrier device |
US9427423B2 (en) * | 2009-03-10 | 2016-08-30 | Atrium Medical Corporation | Fatty-acid based particles |
US9278161B2 (en) | 2005-09-28 | 2016-03-08 | Atrium Medical Corporation | Tissue-separating fatty acid adhesion barrier |
US8574627B2 (en) | 2006-11-06 | 2013-11-05 | Atrium Medical Corporation | Coated surgical mesh |
US9492596B2 (en) | 2006-11-06 | 2016-11-15 | Atrium Medical Corporation | Barrier layer with underlying medical device and one or more reinforcing support structures |
MX2011009919A (en) | 2009-04-03 | 2012-01-20 | Cook Composites & Polymers | Thermosetting compositions containing isocyanurate rings. |
US20110038910A1 (en) | 2009-08-11 | 2011-02-17 | Atrium Medical Corporation | Anti-infective antimicrobial-containing biomaterials |
US10322213B2 (en) | 2010-07-16 | 2019-06-18 | Atrium Medical Corporation | Compositions and methods for altering the rate of hydrolysis of cured oil-based materials |
US9867880B2 (en) | 2012-06-13 | 2018-01-16 | Atrium Medical Corporation | Cured oil-hydrogel biomaterial compositions for controlled drug delivery |
FR2993439B1 (en) * | 2012-07-20 | 2014-07-25 | Albea Services | COLD APPLICATOR TIP |
US9371468B2 (en) | 2013-01-16 | 2016-06-21 | Composites Intellectual Holdings, Inc. | Co-cured gel coats, elastomeric coatings, structural layers, and in-mold processes for their use |
US10239265B2 (en) | 2013-03-15 | 2019-03-26 | Composites Intellectual Holdings, Inc. | Structural composite preform wet-out and curing system and method |
KR102428000B1 (en) | 2014-10-31 | 2022-08-02 | 다우 글로벌 테크놀로지스 엘엘씨 | Process for in situ water removal from an oxidative esterification reaction using a coupled reactor-distillation system |
US10160882B2 (en) * | 2015-02-26 | 2018-12-25 | Polynt Composites USA, Inc. | Fillers |
US10329763B2 (en) | 2016-02-24 | 2019-06-25 | Wabash National, L.P. | Composite floor structure and method of making the same |
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JPS55115445A (en) * | 1979-02-28 | 1980-09-05 | Nippon Gakki Seizo Kk | Gel coat composition |
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JPH02102156A (en) | 1988-10-12 | 1990-04-13 | Hitachi Chem Co Ltd | Production of semitransparent artificial stone |
US5244941A (en) * | 1989-11-02 | 1993-09-14 | Ralph Wilson Plastics Company | Artificial stone compositions, process of producing the same, and apparatus employed in the production thereof |
US5102764A (en) * | 1989-12-15 | 1992-04-07 | Eastman Kodak Company | Styrene butylacrylate toner with magenta dye |
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DE69226200T2 (en) * | 1991-11-07 | 1999-03-11 | Akbar Ghahary | MINERAL-LIKE PLASTICS |
US5504126A (en) * | 1991-11-07 | 1996-04-02 | Safas Corporation | Mineral-like coating and methods of using same |
JPH0625539A (en) | 1992-01-23 | 1994-02-01 | Yamaha Corp | Colored resin particle for decorated molding |
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JP2001279113A (en) * | 2000-03-30 | 2001-10-10 | Mode Center:Kk | Material for resin molding and resin molded article using the same |
JP2002220473A (en) * | 2001-01-25 | 2002-08-09 | Japan U-Pica Co Ltd | Production method for cured-resin fine powder |
JP2003002995A (en) | 2001-06-20 | 2003-01-08 | Tokyo Printing Ink Mfg Co Ltd | Suede-like frp molded product and method for producing the same |
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EA019218B1 (en) | 2014-02-28 |
EP2097479B1 (en) | 2010-06-30 |
US20080160307A1 (en) | 2008-07-03 |
BRPI0722052A2 (en) | 2014-04-01 |
EA200970653A1 (en) | 2009-12-30 |
KR101468240B1 (en) | 2014-12-03 |
AU2007341656B2 (en) | 2013-10-10 |
AU2007341656A1 (en) | 2008-07-10 |
ATE472575T1 (en) | 2010-07-15 |
PL2097479T3 (en) | 2010-12-31 |
BRPI0722052B1 (en) | 2018-11-13 |
KR20090103898A (en) | 2009-10-01 |
US8906502B2 (en) | 2014-12-09 |
MX2009006426A (en) | 2009-08-20 |
DE602007007516D1 (en) | 2010-08-12 |
ES2347922T3 (en) | 2010-11-25 |
WO2008080550A1 (en) | 2008-07-10 |
CA2671089C (en) | 2014-07-15 |
MY152134A (en) | 2014-08-15 |
CA2671089A1 (en) | 2008-07-10 |
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